Vehicle energy-storage systems having parallel cooling

ABSTRACT

Provided are systems for vehicle energy storage having parallel cooling comprising a plurality of modules. Each module may comprise two half modules coupled together. Each half module can include a plurality of battery cells. A current carrier of each half module may be electrically coupled to the cells. The cells may be disposed between the current carrier and a plate. Each half module can have the cells, current carrier, and blast plate disposed in an enclosure. The enclosure can have a coolant sub-system for circulating coolant in parallel to the plurality of cells such that each of the battery cells is at approximately the same predetermined temperature. The modules may be disposed in a tray. A coolant system may be provided for circulating coolant across the plurality of modules in parallel such that each of the modules can be maintained at approximately the same predetermined temperature.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 14/868,234, filed Sep. 28, 2015, which is a continuation ofU.S. patent application Ser. No. 14/841,617, filed Aug. 31, 2015, whichclaims the benefit of U.S. Provisional Application No. 62/186,977, filedon Jun. 30, 2015. The subject matter of the aforementioned applicationsis incorporated herein by reference for all purposes.

FIELD

The present application relates generally to energy-storage systems, andmore specifically to energy-storage systems for vehicles.

BACKGROUND

It should not be assumed that any of the approaches described in thissection qualify as prior art merely by virtue of their inclusion in thissection.

Electric-drive vehicles offer a solution for reducing the impact offossil-fuel engines on the environment and transforming automotivemobility into a sustainable mode of transportation. Energy-storagesystems are essential for electric-drive vehicles, such as hybridelectric vehicles, plug-in hybrid electric vehicles, and all-electricvehicles. However, present energy-storage systems have disadvantagesincluding large size, inefficiency, and poor safety, to name a few.Similar to many sophisticated electrical systems, heat in automotiveenergy-storage systems should be carefully managed. Current thermalmanagement schemes consume an inordinate amount of space. Presentenergy-storage systems also suffer from inefficiencies arising variouslyfrom imbalance among battery cells and resistance in various electricalconnections. In addition, current energy-storage systems are notadequately protected from forces such as crash forces encountered duringa collision.

SUMMARY

This summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This summary is not intended to identify key features oressential features of the claimed subject matter, nor is it intended tobe used as an aid in determining the scope of the claimed subjectmatter.

According to various embodiments, the present technology may be directedto vehicle energy-storage systems having parallel cooling comprising: aplurality of modules, each module comprising two half modules coupledtogether, each half module including: a plurality of battery cells, thebattery cells being cylindrical rechargeable battery cells each having afirst end and a second end, the first end distal from the second end,and having an anode terminal and a cathode terminal being disposed atthe first end; a current carrier electrically coupled to the batterycells, the cathode terminal of each of the battery cells being coupledto a respective first contact of the current carrier, the anode terminalof each of the battery cells being coupled to a respective secondcontact of the current carrier; a plate disposed substantially parallelto the current carrier such that the battery cells are disposed betweenthe current carrier and the plate; and an enclosure having the batterycells, current carrier, and plate disposed therein, the enclosurecomprising: a coolant input port; a coolant output port; and a powerconnector electrically coupled to the current carrier, the enclosurehaving a coolant sub-system for circulating coolant flowing into theenclosure through the coolant input port and out of the enclosurethrough the coolant output port in parallel such that each of thebattery cells is at approximately the same predetermined temperature; atray having the plurality of modules disposed therein; and a coolantsystem for circulating coolant flowing into the tray across theplurality of modules and battery cells in parallel such that each of themodules is at approximately the same predetermined temperature.

In some embodiments, the vehicle energy-storage system may also includea plurality of intumescent material sheets that are flame-activated toredirect flames during a thermal event away from the battery modules andhigh voltage connections.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments are illustrated by way of example and not limitation in thefigures of the accompanying drawings, in which like references indicatesimilar elements.

FIG. 1 illustrates an example environment in which an energy-storagesystem can be used.

FIG. 2A shows an orientation of battery modules in an energy-storagesystem, according to various embodiments of the present disclosure.

FIG. 2B depicts a bottom part of an enclosure of a partial battery packsuch as shown in FIG. 2A.

FIG. 3 is a simplified diagram illustrating coolant flows, according toexample embodiments.

FIG. 4 is a simplified diagram of a battery module, according to variousembodiments of the present disclosure.

FIG. 5 illustrates a half module, in accordance with variousembodiments.

FIGS. 6A and 6B show a current carrier, according to variousembodiments.

FIG. 7 depicts an example battery cell.

FIGS. 8 and 9 illustrate further embodiments of a battery module.

FIGS. 10A and 10B show battery module coupling, according to someembodiments.

DETAILED DESCRIPTION

While this technology is susceptible of embodiment in many differentforms, there are shown in the drawings and will herein be described indetail several specific embodiments, with the understanding that thepresent disclosure is to be considered as an exemplification of theprinciples of the technology and is not intended to limit the technologyto the embodiments illustrated. The terminology used herein is for thepurpose of describing particular embodiments only and is not intended tobe limiting of the technology. As used herein, the singular forms “a,”“an,” and “the” are intended to include the plural forms as well, unlessthe context clearly indicates otherwise. It will be further understoodthat the terms “comprises,” “comprising,” “includes,” and “including,”when used in this specification, specify the presence of statedfeatures, integers, steps, operations, elements, and/or components, butdo not preclude the presence or addition of one or more other features,integers, steps, operations, elements, components, and/or groupsthereof. It will be understood that like or analogous elements and/orcomponents, referred to herein, may be identified throughout thedrawings with like reference characters. It will be further understoodthat several of the figures are merely schematic representations of thepresent technology. As such, some of the components may have beendistorted from their actual scale for pictorial clarity.

Some embodiments of the present invention can be deployed in a wheeled,self-powered motor vehicle used for transportation, such as hybridelectric vehicles, plug-in hybrid electric vehicles, and all-electricvehicles. For example, FIG. 1 illustrates an electric car 100. Electriccar 100 is an automobile propelled by one or more electric motors 110.Electric motor 110 can be coupled to one or more wheels 120 through adrivetrain (not shown in FIG. 1). Electric car 100 can include a frame130 (also known as an underbody or chassis). Frame 130 is a supportingstructure of electric car 100 to which other components can beattached/mounted, such as, for example, a battery pack 140 a. Batterypack 140 a can supply electricity to power one or more electric motors110, for example, through an inverter. The inverter can change directcurrent (DC) from battery pack 140 a to alternating current (AC), asrequired for electric motors 110, according to some embodiments.

As depicted in FIG. 1, battery pack 140 a may have a compact “footprint”and be at least partially enclosed by frame 130 and disposed to providea predefined separation, e.g. from structural rails 150 of an upper bodythat couples to frame 130. Accordingly, at least one of a rear crumplezone 160, a front crumple zone 170, and a lateral crumple zone 180 canbe formed around battery pack 140 a. Both the frame 130 and structuralrails 150 may protect battery pack 140 a from forces or impacts exertedfrom outside of electric car 100, for example, in a collision. Incontrast, other battery packs which extend past at least one ofstructural rails 150, rear crumple zone 160, and front crumple zone 170remain vulnerable to damage and may even explode in an impact.

Battery pack 140 a may have a compact “footprint” such that it may beflexibly used in and disposed on frame 130 having different dimensions.Battery pack 140 a can also be disposed in frame 130 to help improvedirectional stability (e.g., yaw acceleration). For example, batterypack 140 a can be disposed in frame 130 such that a center of gravity ofelectric car 100 is in front of the center of the wheelbase (e.g.,bounded by a plurality of wheels 120).

FIG. 2A shows a battery pack 140 b with imaginary x-, y-, and z-axissuperimposed, according to various embodiments. Battery pack 140 b caninclude a plurality of battery modules 210. In the non-limiting example,battery pack 140 b can be approximately 1000 mm wide (along x-axis),1798 mm long (along y-axis), and 152 mm high (along z-axis), and caninclude 36 of battery modules 210.

FIG. 2B illustrates an exemplary enclosure 200 for battery pack 140 bhaving a cover removed for illustrative purposes. Enclosure 200 includestray 260 and a plurality of battery modules 210. The tray 260 mayinclude a positive bus bar 220 and a negative bus bar 230. Positive busbar 220 can be electrically coupled to a positive (+) portion of a powerconnector of each battery module 210. Negative bus bar 230 can beelectrically coupled to a negative (−) portion of a power connector ofeach battery module 210. Positive bus bar 220 is electrically coupled toa positive terminal 240 of enclosure 200. Negative bus bar 230 can beelectrically coupled to a negative terminal 250 of enclosure 200. Asdescribed above with reference to FIG. 1, because bus bars 220 and 230are within structural rails 150, they can be protected from collisiondamage. In some embodiments, flame-activated intumescent sheets 270 canbe included at the corners of the battery pack so that, in the event ofa battery-pack level thermal runaway event (e.g., a fire), the materialcan swell to seal the gap between battery strings 212 and high voltagebattery pack connections to slow down or halt propagation of the thermalrunaway event.

According to some embodiments, negative bus bar 230 and positive bus bar220 are disposed along opposite edges of tray 260 to provide apredefined separation between negative bus bar 230 and positive bus bar220. Such separation between negative bus bar 230 and positive bus bar220 can prevent or at least reduce the possibility of a short circuit(e.g., of battery pack 140 b) due to a deformity caused by an impact.

As will be described further in more detail with reference to FIG. 5,battery module 210 can include at least one battery cell (details notshown in FIG. 2A, see FIG. 7). The at least one battery cell can includean anode terminal, a cathode terminal, and a cylindrical body. Thebattery cell can be disposed in each of battery module 210 such that asurface of the anode terminal and a surface of the cathode terminal arenormal to the imaginary x-axis referenced in FIG. 2A (e.g., thecylindrical body of the battery cell is parallel to the imaginaryx-axis). This can be referred to as an x-axis cell orientation.

In the event of fire and/or explosion in one or more of battery modules210, the battery cells can be vented along the x-axis, advantageouslyminimizing a danger and/or a harm to a driver, passenger, cargo, and thelike, which may be disposed in electric car 100 above battery pack 140 b(e.g., along the z-axis), in various embodiments. As further support,sheets of flame-activated intumescent material 920 can be included invarious embodiments atop the exterior of battery modules as shown inFIG. 9 to seal off gaps and redirect flames away from the passengercompartment, other battery modules 210, or the high voltage busconnections 240 and 250.

The x-axis cell orientation of battery modules 210 in battery pack 140 bshown in FIGS. 2A and 2B can be advantageous for efficient electricaland fluidic routing to each of battery module 210 in battery pack 140 b.For example, at least some of battery modules 210 can be electricallyconnected in a series forming string 212, and two or more of string 212can be electrically connected in parallel. This way, in the event one ofstring 212 fails, others of string 212 may not be affected, according tovarious embodiments.

FIG. 3 illustrates coolant flows and operation of a coolant system and acoolant sub-system according to various embodiments. As shown in FIG. 3,the x-axis cell orientation can be advantageous for routing coolant(cooling fluid) in parallel to each of battery modules 210 in batterypack 140 b. Coolant can be pumped into battery pack 140 b at ingress 310and pumped out of battery pack 140 b at egress 320. A resulting pressuregradient within battery pack 140 b can provide sufficient circulation ofcoolant to minimize a temperature gradient within battery pack 140 b(e.g., a temperature gradient within one of battery modules 210, atemperature gradient between battery modules 210, and/or a temperaturegradient between two or more of string 212 shown in FIG. 2A).

Within battery pack 140 b, the coolant system may circulate the coolant,for example, to battery modules 210 (e.g., the circulation is indicatedby reference numeral 330). One or more additional pumps (not shown inFIG. 3) can be used to maintain a roughly constant pressure betweenmultiple battery modules 210 connected in series (e.g., in string 212 inFIG. 2A) and between such strings. Within each battery module 210, thecoolant sub-system may circulate the coolant, for example, between andwithin two half modules 410 and 420 shown in FIG. 4 (e.g., thecirculation indicated by reference numeral 340). In some embodiments,the coolant can enter each battery module 210 through an interface 350between two half modules 410 and 420, in a direction (e.g., along the y-or z-axis) perpendicular to the cylindrical body of each battery cell,and flow to each cell. Driven by pressure within the coolant system, thecoolant then can flow along the cylindrical body of each battery (e.g.,along the x-axis) and may be collected at the two (opposite) sidesurfaces 360A and 360B of the module that can be normal to the x-axis.In this way, heat can be efficiently managed/dissipated and thermalgradients minimized among all battery cells in battery pack 140 b, suchthat a temperature may be maintained at an approximately uniform level.

In some embodiments, parallel cooling, as illustrated in FIG. 3, canmaintain temperature among battery cells in battery pack 140 b at anapproximately uniform level such that a direct current internalresistance (DCIR) of each battery cell is maintained at an substantiallypredefined resistance. The DCIR can vary with a temperature, therefore,keeping each battery cell in battery pack 140 b at a substantiallyuniform and predefined temperature can result in each battery cellhaving substantially the same DCIR. Since a voltage across each batterycell can be reduced as a function of its respective DCIR, each batterycell in battery pack 140 b may experience substantially the same loss involtage. In this way, each battery cell in battery pack 140 b can bemaintained at approximately the same capacity and imbalances betweenbattery cells in battery pack 140 b can be minimized.

In some embodiments, when compared to techniques using metal tubes tocirculate coolant, parallel cooling can enable higher battery celldensity within battery module 210 and higher battery module density inbattery pack 140 b. In some embodiments, coolant or cooling fluid may beat least one of the following: synthetic oil, for example,poly-alpha-olefin (or poly-α-olefin, also abbreviated as PAO) oil,ethylene glycol and water, liquid dielectric cooling based on phasechange, and the like.

FIG. 4 illustrates battery module 210 according to various embodiments.A main power connector 460 can provide power from battery cells 450 tooutside of battery module 210. In some embodiments, battery module 210can include two half modules 410 and 420, each having an enclosure 430.Enclosure 430 may be made using one or more plastics having sufficientlylow thermal conductivities. Respective enclosures 430 of each of the twohalf modules 410 and 420 may be coupled with each other to form thehousing for battery module 210.

FIG. 4 includes a view 440 of enclosure 430 (e.g., with a coverremoved). For each of half modules 410, 420 there is shown a pluralityof battery cells 450 oriented (mounted) horizontally (see also FIG. 5and FIG. 8). By way of non-limiting example, each half module includesone hundred four of battery cells 450. By way of further non-limitingexample, eight of battery cells 450 are electrically connected in aseries (e.g., the staggered column of eight battery cells 450 shown inFIG. 4), with a total of thirteen of such groups of eight battery cells450 electrically connected in series. By way of additional non-limitingexample, the thirteen groups (e.g., staggered columns of eight batterycells 450 electrically coupled in series) are electrically connected inparallel. This example configuration may be referred to as “8S13P” (8series, 13 parallel). In some embodiments, the 8S13P electricalconnectivity can be provided by current carrier 510, described furtherbelow in relation to FIGS. 5 and 6. Other combinations and permutationsof battery cells 450 electrically coupled in series and/or parallelmaybe used.

FIG. 5 depicts a view of half modules 410, 420 without enclosure 430 inaccordance with various embodiments. Half modules 410 and 420 need notbe the same, e.g., they may be mirror images of each other in someembodiments. Half modules 410 and 420 can include a plurality of batterycells 450. The plurality of battery cells 450 can be disposed betweencurrent carrier 510 and blast plate 520 such that an exterior side ofeach of battery cells 450 is not in contact with the exterior sides ofother (e.g., adjacent) battery cells 450. In this way, coolant cancirculate among and between battery cells 450 to provide submerged,evenly distributed cooling. In addition, to save the weight associatedwith coolant in areas where cooling is not needed, air pockets can beformed using channels craftily designed in the space 530 between currentcarrier 510 and blast plate 520 not occupied by battery cells 450.Coolant can enter half modules 410, 420 through coolant intake 540, isoptionally directed by one or more flow channels, circulates among andbetween the plurality of battery cells 450, and exits through coolantouttake 550. In some embodiments, coolant intake 540 and coolant outtake550 can each be male or female fluid fittings. In some embodiments,coolant or cooling fluid is at least one of: synthetic oil such aspoly-alpha-olefin (or poly-α-olefin, abbreviated as PAO) oil, ethyleneglycol and water, liquid dielectric cooling based on phase change, andthe like. Compared to techniques using metal tubes to circulate coolant,submerged cooling improves a packing density of battery cells 450 (e.g.,inside battery module 210 and half modules 410, 420) by 15%, in variousembodiments.

FIGS. 6A and 6B depict current carrier 510, 510A according to variousembodiments. Current carrier 510, 510A is generally flat (or planar) andcomprises one or more layers (not shown in FIGS. 6A and 6B), such as abase layer, a positive power plane, a negative power plane, and signalplane sandwiched in-between dielectric isolation layers (e.g., made ofpolyimide). In some embodiments, the signal plane can include signaltraces and be used to provide battery module telemetry (e.g., batterycell voltage, current, state of charge, and temperature from optionalsensors on current carrier 510) to outside of battery module 210.

As depicted in FIG. 6B, current carrier 510A can be a magnified view ofa portion of current carrier 510, for illustrative purposes. Currentcarrier 510A can be communicatively coupled to each of battery cells450, for example, at a separate (fused) positive (+) portion 630 and aseparate negative (−) portion 640 which may be electrically coupled tothe positive power plane and negative power plane (respectively) ofcurrent carrier 510A, and to each cathode and anode (respectively) of abattery cell 450. In some embodiments, positive (+) portion 630 can belaser welded to a cathode terminal of battery cell 450, and negative (−)portion 640 can be laser welded to an anode terminal of battery cell450. In some embodiments, the laser-welded connection can have on theorder of 5 milli-Ohms resistance. In contrast, electrically coupling theelements using ultrasonic bonding of aluminum bond wires can have on theorder of 10 milli-Ohms resistance. Laser welding advantageously can havelower resistance for greater power efficiency and take less time toperform than ultrasonic wire bonding, which can contribute to greaterperformance and manufacturing efficiency.

Current carrier 510A can include a fuse 650 formed from part of a metallayer (e.g., copper, aluminum, etc.) of current carrier 510A, such as inthe positive power plane. In some embodiments, the fuse 650 can beformed (e.g., laser etched) in a metal layer (e.g., positive powerplane) to dimensions corresponding to a type of low-resistance resistorand acts as a sacrificial device to provide overcurrent protection. Forexample, in the event of thermal runaway of one of battery cell 450(e.g., due to an internal short circuit), the fuse may “blow,” breakingthe electrical connection to the battery cell 450 and electricallyisolating the battery cell 450 from current carrier 510A. Although anexample of a fuse formed in the positive power plane is provided, a fusemay additionally or alternatively be a part of the negative power plane.

Additional thermal runaway control can be provided in variousembodiments by scoring on end 740 (identified in FIG. 7) of the batterycell 450. The scoring can promote rupturing to effect venting in theevent of over pressure. In various embodiments, all battery cells 450may be oriented to allow venting into the blast plate 520 for both halfmodules.

In some embodiments, current carrier 510 can be comprised of a printedcircuit board and a flexible printed circuit. For example, the printedcircuit board may variously comprise at least one of copper, FR-2(phenolic cotton paper), FR-3 (cotton paper and epoxy), FR-4 (wovenglass and epoxy), FR-5 (woven glass and epoxy), FR-6 (matte glass andpolyester), G-10 (woven glass and epoxy), CEM-1 (cotton paper andepoxy), CEM-2 (cotton paper and epoxy), CEM-3 (non-woven glass andepoxy), CEM-4 (woven glass and epoxy), and CEM-5 (woven glass andpolyester). By way of further non-limiting example, the flexible printedcircuit may comprise at least one of copper foil and a flexible polymerfilm, such as polyester (PET), polyimide (PI), polyethylene naphthalate(PEN), polyetherimide (PEI), along with various fluoropolymers (FEP),and copolymers.

In addition to electrically coupling battery cells 450 to each other(e.g., in series and/or parallel), current carrier 510 can provideelectrical connectivity to outside of battery module 210, for example,through main power connector 460 (FIG. 4). Current carrier 510 may alsoinclude electrical interface 560 (FIGS. 5, 6A) which transports signalsfrom the signal plane. Electrical interface 560 can include anelectrical connector (not shown in FIGS. 5, 6A).

FIG. 7 shows battery cell 450 according to some embodiments. In someembodiments, battery cell 450 can be a lithium ion (li-ion) battery. Forexample, battery cell 450 may be an 18650 type li-ion battery having acylindrical shape with an approximate diameter of 18.6 mm andapproximate length of 65.2 mm. Other rechargeable battery form factorsand chemistries can additionally or alternatively be used. In variousembodiments, battery cell 450 may include can 720 (e.g., the cylindricalbody), anode terminal 770, and cathode terminal 780. For example, anodeterminal 770 can be a negative terminal of battery cell 450 and cathodeterminal 780 can be a positive terminal of battery cell 450. Anodeterminal 770 and cathode terminal 780 can be electrically isolated fromeach other by an insulator or dielectric.

FIG. 8 illustrates another example of a battery module, battery module210 b, according to various embodiments. As described in relation tobattery module 210 in FIG. 4, battery module 210 b may include two halfmodules 410 and 420 and main power connector 460. Each of half modules410 and 420 may include one of enclosure 430 for housing battery cellstherein. Battery module 210 b further depicts main coolant input port820, main coolant output port 810, and communications and low powerconnector 830. Coolant can be provided to battery module 210 b at maincoolant input port 820, circulated within battery module 210 b, andreceived at main coolant output port 810.

In contrast to the view of battery module 210 in FIG. 4, FIG. 8 depictscurrent carrier 510. Battery module 210 b may include one or morestaking features 840 to hold current carrier 510 in battery module 210b. For example, staking feature 840 can be a plastic stake. In someembodiments, communications and low power connector 830 can be at leastpartially electrically coupled to the signal plane and/or electricalinterface 560 of current carrier 510, for example, through electronicsfor data acquisition and/or control (not shown in FIG. 8).Communications and low power connector 830 may provide low power, forexample, to electronics for data acquisition and/or control, andsensors.

FIG. 9 shows another view of battery module 210 b where the batterycells and the current carrier are removed from one of the half modules,for illustrative purposes. As described in relation to FIGS. 4 and 8,battery module 210 b may include two half modules 410 and 420, mainpower connector 460, main coolant output port 810, main coolant inputport 820, and communications and low power connector 830. Each of thehalf modules 410 and 420 can include an enclosure 430. Each enclosure430 may further include plate 910 (e.g., a bracket). Plate 910 mayinclude structures for securing the battery cells within enclosure 430and maintaining the distance between battery cells. Flame-activatedintumescent sheets 920 are available in some embodiments to slow or haltpropagation of thermal runaway events from one battery module 210 to anyothers in the battery pack 140 b. These sheets may be affixed to thebottom of battery tray cover or along the top of battery modules 210with any of various fixturing elements such as adhesive strips, bolts,or grips. Other embodiments may include fixturing these intumescentsheets 920 in other strategic locations around battery modules 210 suchas below, in between, or along the sides.

FIGS. 10A and 10B illustrate arrangement and coupling between two ofbattery modules 210 b: 210 ₁ and 210 ₂. From different perspectiveviews, FIG. 10A depicts battery modules 210 ₁ and 210 ₂ being apart andaligned for coupling. For example, battery modules 210 ₁ and 210 ₂ arepositioned as shown in FIG. 10A and moved together until coupled asshown in the example in FIG. 10B. Generally, a female receptacle on oneof battery modules 210 ₁ and 210 ₂ may receive and hold a male connectoron the other of battery modules 210 ₂ and 210 ₁, respectively.

As shown in the example in FIG. 10A, a left side of battery modules 210₁ and 210 ₂ may have male connectors and a right side of battery modules210 ₁ and 210 ₂ have female connectors, according to some embodiments.For example, the left sides of battery modules 210 ₁ and 210 ₂ includemale main power connector 460 _(M), male main coolant output port 810_(M), male main coolant input port 820 _(M), and male communications andlow power connector 830 _(M). By way of further non-limiting example,the right sides of battery modules 210 ₁ and 210 ₂ can include femalemain power connector 460 _(F), female main coolant output port 810 _(F),female main coolant input port 820 _(F), and female communications andlow power connector 830 _(F). Each of female main power connector 460_(F), female main coolant output port 810 _(F), female main coolantinput port 820 _(F), and female communications and low power connector830 _(F) may include an (elastomer) o-ring or other seal. Othercombinations and permutations of male and female connectors—such as amix of male and female connectors on each side, and female connectors onthe right side and male connectors on the left side—may be used.

FIG. 10B depicts a cross-sectional view of battery modules 210 ₁ and 210₂ of FIG. 10A coupled together. For example, male main power connector460 _(M) and female main power connector 460 _(F) (FIG. 10A) can combineto form coupled main power connectors 460 _(C), male main coolant outputport 810 _(M) and female main coolant output port 810 _(F) can combineto form coupled main coolant output ports 810 _(C), male main coolantinput port 820 _(M) and female main coolant input port 820 _(F) cancombine to form coupled main coolant input ports 820 _(C) (not shown inFIG. 10B), and female communications and low power connector 830 _(F)and male communications and low power connector 830 _(M) can combine toform coupled communications and low power connectors 830 _(C). As aresult, the internal cooling channels or manifolds of the batterymodules can be connected through the coupling between the modules,forming the cooling system schematically illustrated in FIG. 3.

As would be readily appreciated by one of ordinary skill in the art,various embodiments described herein may be used in additionalapplications, such as in energy-storage systems for wind and solar powergeneration. Other applications are also possible.

The description of the present technology has been presented forpurposes of illustration and description, but is not intended to beexhaustive or limited to the invention in the form disclosed. Manymodifications and variations will be apparent to those of ordinary skillin the art without departing from the scope and spirit of the invention.Exemplary embodiments were chosen and described in order to best explainthe principles of the present technology and its practical application,and to enable others of ordinary skill in the art to understand theinvention for various embodiments with various modifications as aresuited to the particular use contemplated.

What is claimed is:
 1. An energy-storage system having parallel coolingcomprising: a plurality of modules, each module comprising two halfmodules coupled together, each half module including: a plurality ofbattery cells, the battery cells being cylindrical rechargeable batterycells each having a first end and a second end, the first end distalfrom the second end, and having an anode terminal and a cathode terminalbeing disposed at the first end; a current carrier electrically coupledto the battery cells, the cathode terminal of each of the battery cellsbeing coupled to a respective first contact of the current carrier, theanode terminal of each of the battery cells being coupled to arespective second contact of the current carrier; a plate disposedsubstantially parallel to the current carrier such that the batterycells are disposed between the current carrier and the plate; and anenclosure having the battery cells, current carrier, and plate disposedtherein, the enclosure comprising: a coolant input port; a coolantoutput port; and a power connector electrically coupled to the currentcarrier, the enclosure having a coolant sub-system for circulatingcoolant flowing into the enclosure through the coolant input port andout of the enclosure through the coolant output port in parallel to theplurality of battery cells such that each of the battery cells is atapproximately the same predetermined temperature; a plurality ofintumescent material sheets that are flame-activated to redirect flamesduring a thermal event away from the battery modules and high voltageconnections; a tray having the plurality of modules disposed therein;and a coolant system for circulating coolant flowing into the trayacross the plurality of modules in parallel such that each of themodules is at approximately the predetermined temperature.
 2. Theenergy-storage system of claim 1, wherein the coolant system creates apressure gradient for coolant flowing into and out of each module of theplurality of modules disposed in the tray, the pressure gradientproviding circulation of the coolant so as to minimize a temperaturegradient between modules of the plurality of modules.
 3. Theenergy-storage system of claim 1, wherein the cells are disposed betweenthe current carrier and the plate such that an exterior side of each ofthe cells is not in contact with the exterior sides of other cells, thecoolant sub-system circulating coolant among and between the cells toprovide submerged, substantially even distributed cooling.
 4. Theenergy-storage system of claim 1, wherein air pockets are formed usingchannels in a space between the current carrier and the plate that isnot occupied by the cells, the air pockets comprising a fluid other thanthe coolant.
 5. The energy-storage system of claim 4, wherein thecoolant flows through each half module along a cylindrical body of abattery cell within the half module.
 6. The energy-storage system ofclaim 1, wherein the modules are arranged in a plurality of strings,each string of the plurality of strings including a plurality ofmodules.
 7. The energy-storage system of claim 6, wherein the coolantflows through the plurality of strings in parallel and the coolant flowswithin each string of the plurality of strings in parallel.
 8. Theenergy-storage system of claim 1, wherein the coolant comprises at leastone of a synthetic oil, ethylene glycol and water, and a liquiddielectric.
 9. The energy-storage system of claim 1, wherein at leasttwo adjacent modules of the plurality of modules are fluidly andelectrically coupled to each other.
 10. The energy-storage system ofclaim 1, wherein the cells are oriented and mounted horizontally in eachhalf module.
 11. An energy-storage system having parallel coolingcomprising: a plurality of modules in a battery pack, each moduleincluding: a plurality of cells, the cells being cylindricalrechargeable cells; the cells being oriented and mounted horizontally ineach module; a current carrier electrically coupled to the cells, acathode terminal of each of the cells being coupled to a respectivefirst contact of the current carrier, an anode terminal of each of thecells being coupled to a respective second contact of the currentcarrier; a plate disposed substantially parallel to the current carriersuch that the cells are disposed between the current carrier and theplate; and an enclosure having the cells, current carrier, and platedisposed therein, the enclosure comprising a coolant sub-system forcirculating coolant flowing into the enclosure through a coolant inputport and out of the enclosure through a coolant output port, the cellsbeing disposed between the current carrier and the plate such that anexterior side of each of the cells is not in contact with the exteriorsides of other cells, the coolant sub-system circulating coolant inparallel among and between the cells to provide submerged, distributedcooling such that each of the cell is at approximately the samepredetermined temperature; a plurality of intumescent material sheetsthat are flame-activated to redirect flames during a thermal event awayfrom the battery modules and high voltage connections; a tray having theplurality of modules disposed therein; and a coolant system forcirculating coolant flowing into the tray across the plurality ofmodules in parallel such that each of the modules is at approximatelythe same predetermined temperature.
 12. The energy-storage system ofclaim 11, wherein the coolant system creates a pressure gradient forcoolant flowing into the battery pack and out of the battery pack, thepressure gradient within the battery pack providing circulation of thecoolant so as to minimize a temperature gradient within the batterypack.
 13. The energy-storage system of claim 11, wherein the cells aredisposed between the current carrier and the plate such that an exteriorside of each of the cells is not in contact with the exterior sides ofother cells, the coolant sub-system circulating coolant among andbetween the cells to provide submerged, substantially even distributedcooling.
 14. The energy-storage system of claim 11, wherein air pocketsare formed using channels in a space between the current carrier and theplate that is not occupied by the cells, the air pockets comprising afluid other than the coolant.
 15. The energy-storage system of claim 14,wherein the coolant flows through each module along a cylindrical bodyof a battery cell within the module.
 16. The energy-storage system ofclaim 11, wherein the modules are arranged in a plurality of strings,each string of the plurality of strings including a plurality ofmodules.
 17. The energy-storage system of claim 16, wherein the coolantflows through the plurality of strings in parallel and the coolant flowswithin each string of the plurality of strings in parallel.
 18. Theenergy-storage system of claim 11, wherein the coolant comprises atleast one of a synthetic oil, ethylene glycol and water, and a liquiddielectric.
 19. The energy-storage system of claim 11, wherein at leasttwo adjacent modules of the plurality of modules are fluidly andelectrically coupled to each other.